Resin Characterization and Control System for 3D Printing
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Solution Overview
Problem
3D printing resins used in additive manufacturing experience chemical and physical property degradation over time, leading to premature depletion, model failures, and wastage, as they lose their ability to properly cure and maintain geometry and surface finish.
Innovation Solution
A system and method utilizing an imaging spectrometer and computing device to characterize and control the chemical properties of in-process resins by determining their life cycle and restoring them to a known state through dilution with a similar resin, thereby preventing premature depletion and model failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin is used continuously for 3D printing, then productivity increases, but resin chemical properties degrade leading to model failures
Solution Approach 1:
The system performs preliminary characterization of resin chemical properties using an imaging spectrometer to establish baseline spectra and identify depletion indicators before model failures occur. This allows proactive detection of resin degradation trends and timely intervention through replacement or regeneration, preventing model crashes while maintaining continuous productivity
Solution Approach 2:
The system implements continuous feedback monitoring by repeatedly characterizing resin spectra during use, comparing against baseline to detect chemical property changes. This real-time feedback enables dynamic adjustment of printing parameters or resin replacement decisions, maintaining model quality while maximizing resin utilization and productivity
2Reliability
If resin is monitored and replaced frequently, then model quality is maintained, but resin waste increases
Solution Approach 1:
Instead of replacing resin at fixed intervals or when complete depletion occurs, the system applies partial monitoring by characterizing only specific spectral regions indicative of resin depletion. This selective approach extends resin useful life by detecting actual chemical changes rather than relying on time-based schedules, reducing waste while maintaining model quality
Solution Approach 2:
The system transforms the approach from time-based resin replacement to parameter-based replacement by monitoring chemical composition changes through spectral analysis. This allows extension of resin usage beyond conventional time limits by continuously tracking actual chemical properties, replacing resin only when specific depletion thresholds are reached, thereby minimizing waste while ensuring model quality
3Measurement precision
If resin chemical properties are monitored, then depletion is detected, but system complexity increases
Solution Approach 1:
The imaging spectrometer serves as an intermediary device that translates complex resin chemical property changes into simple spectral data patterns. By using this intermediary tool, the system achieves precise chemical characterization without requiring direct complex analytical chemistry equipment, maintaining measurement accuracy while managing system complexity through a dedicated specialized component
Solution Approach 2:
The system replaces complex mechanical or manual resin testing methods with optical spectroscopy. Instead of using complicated physical analysis equipment or manual chemical testing procedures, the invention uses non-contact optical spectral analysis to monitor resin properties, substituting a simpler optical measurement system for more complex traditional characterization methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively mitigates resin waste and model failures by maintaining consistent chemical properties, ensuring the resin remains usable until its physical quantity is consumed, reducing costs and improving the quality of 3D printed components.
Implementation Method 1
an imaging spectrometer that outputs one or more first spectrums that define at least one absorbance or emissions value versus a spectral range of wavenumbers for the in-process resin
Data Source
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AI summary
The present disclosure is directed to a method of altering chemical properties of an in-process resin (116) used with a 3D printing apparatus (110). The method includes monitoring the in-process resin (116) using an imaging spectrometer (120), comparing the in-process resin (116) and a model (112) using one or more spectrums (121, 122, 123) from the imaging spectrometer (120), and diluting the in-process resin (116) with a diluting resin.